Method of making pile fabrics



J" 24,. M c. F. TAUBERT METHOD OF MAKING FILE FABRICS Filed June 24, 1947 0 a ,w E 4 ErMW/M Wk (W I! V a W l )1 r mg i F yr. & Z n FM W Vvlll su llll iqfl.

Patented Jan. 24, 1950 2,495,666 METHOD OF MAKING PILE FABRICS Charles F. Taubert,

Scarsdale, N. Y., assignor of Iozngghalf to Elizabeth H. Taubert, Scarsdale,

Application June 24, 1947, Serial No. 756,602

(Cl. l54-77) 8 Claims.

This invention relates to the manufacture of rugs. and more particularly to a new method of manufacture which eliminates the costly looms necessary in ordinary rug making.

An object of the invention is to provide a closely tufted rug having a rubber or synthetic back.

A further object of the invention is to eliminate the costly machinery and the necessity for highly skilled labor in the manufacture of the rugs.

A further object is to provide a rug having a large number of piles so as to compare favorably with the more expensive woven rugs.

Other objects and advantages of my invention will appear from the following description and the accompanying drawings.

Fig. 1 is a view in cross section showing the manner in which yarn is handled in the exercise of my invention.

Fig. 2 is a sectional view showing the manner in which the yarn is locked in the pattern board.

Fig. 3 is a top plan view of the pattern board adapted to be used in the exercise of my invention.

Fig. 4 is a detailed view showing one step in the operation.

Fig. 5 is a view invention.

Fig. 6 is a view showing the yarn confined and free.

Fig. 7 is a detailed view showing the manner in which the yarn expands when the confining element is removed.

The essential feature of my invention is that I confine yarn in such a way that it may be readily handled and a great many more piles inserted in a given area than if the yarn were free. Then,

illustrating another step in my after the rug has been constructed the yarn is freed and expanded so as to make the proper surface. It is well known that wool and other yarn is highly compressible and resilient. In preparing yarn for use in my improved method the wool yarn is covered with a braid of rayon manufactured by the acetate process. In the braiding operation maximum tension is put on the rayon in order to compress the wool yarn to a diameter much smaller than that of its natural state and to give the resultant product a degree of rigidity. In practice it is possible to compress certain yarns to approximately one-tenth of their normal diameter.

Referring to Fig. 7 the illustrated yarn in is compressed by the braided rayon covering it. The rayon covered wool is then inserted into a pattern board. The pattern board will vary considerably, depending upon the size of the rug,

:55 do not wish the number of holes per square inch and other elements. In order to demonstrate my invention I have shown a pattern board I5 consisting of three layers I6, I! and I8 held together by suitable bolts IS. The opening 20 in the intermediate I board is larger than the diameter of the bolts l9 so that the intermediate board I! may be slid or shifted with relation to the other layers.

one-quarter of an inch 26. The board is then locked by the shifting of the middle layer I! as shown in Fig. 2 and the yarn is then cut on the top surface 21 of the board to separate it from the continuous length on the spools. This results in a pattern board or frame the liquid. The forms are then placed in suitable curing mechanisms such as ovens where in the case of rubber vulcanization takes place. While I have mentioned rubber as a base for my rug, any suitable material such as thermo-heated plastic may be used if it is flexible enough for the purpose. As soon as the base is vulcanized, or otherwise cured, the frame may be lifted from the pan type form 30, the pattern board unlocked and removed. This leaves a rubber base having many hundreds of rayon covered ends imbedded therein as shown on the left side of Fig. 6. As previously stated, the rayon used in the braiding operation is of the type manufactured by the acetate process. This product is soluble in acetone. The entire product is, therefore, then washed with acetone in closed vessels which dissolves the rayon braid and in turn releases the resilient wool yarn from its compressed condition allowing it to expand, as shown on the right side of Fig. 6. After washing, drying and brushing the finished product is then suitable for use and the expanded yarn has all the advantages of a woven rug. The rubber base makes the rug nons'lip and produces a pusherlike efiect.

While I have described my invention as employing wool yarn covered by braided rayon, I to be limited to these materials as there are many other materials, yarns and synthetic yarns which may be used with the same effect and there are other coverings and solvents which can be used without deviatin from the conceptive idea of my invention.

I claim:

1. A method of manufacturing simulated pile fabric structure which consists of compressing wool yarn in a soluble covering, inserting said yarn in a rubber base and then dissolving the covering on said yarn.

2. A method of manufacturing simulated pile fabric structure which consists in compressing wool yarn by covering it with a soluble braiding, feeding said yarn through a pattern board into a liquid rubber base, vulcanizing said base and freeing said yarn by dissolving the coverin thereon.

3. A method of manufacturing simulated pile fabric structure which consists of compressing wool yarns in'a soluble covering, cutting said yarn to predetermined lengths, inserting one end of said lengths in a rubber base and then dissolving the covering on the free ends of said yarn.

4. A method of manufacturing simulated pile fabric structure which consists in compressing yarn or fibers by covering it with a soluble braid ing braided under tension, feeding said yarn through a pattern board so that the ends extend into a liquid rubber base, cutting said yarn to a predetermined length and then dissolving the soluble braiding to loosen the free ends of said yarn.

5. A method of manufacturing simulated pile fabric structure which consists of compressing wool yarn in an acetate rayon braiding, feeding a series of piles of said yarn through a pattern board so that their ends depend therefrom in close proximity a predetermined distance, cutting the yarn along the top of said pattern board, inserting the depending ends in a curable base,

, 4 cm'ing the base, andthen dissolving the rayon acetate braiding in acetone.

6. In a simulated pile fabric structure comprising a plurality of woolen yarn piles imbedded in a vulcanized rubber base, the portion of .said piles that are imbedded in said base being compressed in a soluble covering and the upper portion of said piles being free of any covering.

'7. A method of making simulated pile fabric structure involving the imbedding of yarn piles in close proximity to each other in a curable bed which includes the step of compressing said yarn to reduce its diameter by covering said yarn with a soluble covering which will compress said yarn in order to permit the insertion of a greater number of piles in a given area and then dissolving the covering on the unimbedded portion of said yarn.

8. A method of manufacturing simulated pile fabric structure which consists of compressing the yarn or fibers in a soluble braiding, feeding a series of piles through a pattern board so that their ends depend therefrom in close proximity for a predetermined distance, cutting the piles along the top of said pattern board, inserting the depending ends in a curable base, curing the base and then dissolving the soluble braiding to allow the free ends of said piles to expand.

CHARLES F. TAUBERT.

REFERENCES CITED The following references are of record in the 

1. A METHOD OF MANUFACTURING SIMULATED PILE FABRIC STRUCTURE WHICH CONSISTS OF COMPRESSING WOOL YARN IN A SOLUBLE COVERING, INSERTING SAID YARN IN A RUBBER BASE AND THEN DISSOLVING THE COVERING ON SAID YARN. 